Spring assembly machines



Aug. 11, 1959 E. L. BRoNsfiEN 23 SPRING ASSEMBLY MACHINES Filed Jan. 20, 1955 15 Sheets-Sheet 1 E. L. BRONSTIEN SPRING ASSEMBLY MACHINES Aug. 11, 1959 15 sheets sheet 2 Filed Jan. 20, 1955 N jmazza w 61ml /vrwizm Aug. 11, 1959 E. L. BRONSTIEN 2,898,950

SPRING ASSEMBLY MACHINES 'Fild Jan. 20, 1955 15 Sheets-Sheet 3 1959 E. L. BRONSTIEN 2,898,950

SPRING ASSEMBLY MACHINES Filed Jan. 20. 1955 15 Sheets-Sheet 4 g I II I V g .2. H IIIIW" Mn N w Aug. 11, 1959 E. L. BRONSTIEN SPRING ASSEMBLY MACHINES l5 Sheets-Sheet 5 Filed Jan. 20, 1955 If; gave 1W dwmllgmwizw W www www Aug. 11, 1959 Filed Jan. 20, 1955 E. L. BRONSTIEN SPRING ASSEMBLY MACHINES 15 Sheets-Sheet 6 Aug. 11, 1959 E. L. BRONSTIYEN 2,898,950

SPRING ASSEMBLY MACHINES Filed Jan. 2O, 1955 l5 Sheets-Sheet 7 146 2450244256? waa/ dlgmwiez Aug. 11, 1959 E. L. BRONSTIEN 2,898,950

' SPRING ASSEMBLY MACHINES Filed Jan. 20, 1955 15 Sheets-Sheet 8 Aug. 11, 1959 E. L. BRONSTIEN SPRING ASSEMBLY MACHINES Fiied Jan. 20, 1955 15 Sheets-Sheet 9 J. g/mafww 1, 1959 E. 1.. BRQNSITIEN 2,898,950

' SPRING ASSEMBLY MACHINES l5 Sheds-Sheet 10 Filed Jan. 20. 1955 HHWEM/ Filed Jag. 20, 1955 Aug. 11, 1959. E. BRQNSTIEN SPRING ASSEMBLY MACHINES Filed Jan. 20, 1955 15 Sheets-Sheet 12 Aug. 11, 1959 E. L. BRQNSTIEN SPRING ASSEMBLY MACHINES 15 Sheets-Sheet 13 Filed Jan 2Q, 1955 E L. BRONSTI'EN SPRING ASSEMBLY MACHINES Aug. 11, 1959 I5 Sheets-Sheet 14.

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SPRING ASSEMBLY MACHINES Filed Jan. 20, 1955 15 Sheets-Sheet 15 FIG- INVENTOR.

'EowAko L BRONS new SPRING ASSEMBILY y 1 Edward L.-/Bronsfien,, St: Raul," Minni, assignorrto The i 5 United StatesBedding Co.,,St. Paul, Minm, a.-.corporation-of 'Minnesota. i

Application January 20; 1955; Serial Ne. 482,943

19' Claims; mama-42.8

My-inventiorr relates to spflng assembly machines, and is I an improvement over the-type-of maehineof United States Letters Patent No. 2,351,659, dated-IuneZO, 19'44, whichxissued on an application filed in the name'of'my; self and another. I

This: application is" a continuation in part" of applicatitan-216,219 fiiedMarch 17, 19-51.

ice

Figure 1 is a front elevationalview of'the right hand portion of amachineembodyjnga form of my invention;

Figure la is a front elevational view, partly; broken away, showing the left hand portionof the machineiof Figure-1; p

Figure 2is a rear elevational view ofthe. upper: right handend of Figure l; I

Figure; 3" is a vertical; sectional view tak'enon the line 3 '3 ofFi'gure. Z and showingga detail. of the drivihg mechanism;

Figure 4 is a transverse, vertical, sectiontakenionthe My novel machine is particularly designed to fabricare-upholstery springs wherein individual coil springs are arrangedinparallehrows-and the top and bottom coils of the individual springs in adjacent rows are connected by means of helical tiex wires. Springassembliesof this kindare commony used in innerspring; mattresses" and seat cushions,v and for similar purposes.

An: object of my invention isto reducethe-cost' of manufacturing such spring assemblies'by'the provisionof anew and 'improved machine whichreduces the: number of operations to lie-performed'by the operator and elimi nates the separate tie wire forming machines and separate handlingofthe tiewires heretofore required".

Another object of my invention is-toproVide a. new and improvedmachine which is completely automatic, except for the initial insertion of the individual springs, whereby an inexperienced person can be quickly and easily trained to operateoneor more of these machines.

Another object of my inventionis to, provide a machine i the structure shown in'Figure 6;

Figure 5. is aside elevational view, with, parts. broken away; showing theclamp bfars andtheir supporting'and operating mechanism. In thistview thetelamp bars are shown in'retractedpositiom" Figurej6'is a top planviewof the clamp barsof'figure 5; butshowingthese'bars in advanced orclam'ping posh tion' and" engaging ,the spring supporting' dies;

Figure 6'21 is' an. enlarged" detail view showing;the,v en: gagement between. the 'righthand. end of a clampbar and its aligning; cam when in theadvanced. positionlshown in-Figure-j' l v v 1 i Figure 7 is atransverse, vertical sectional. view taken on the line*7=-'7 ofEigure 6, and also 7 -'-7 of Figure 8.;

Figure8"is an enarg ed top plan viewnofa portionof Figure 9 is anelevational view largely, in section of the feed rollers and their driving mechanism, andis taken generally'on' the; line-9'-9,of'Figure 2;

Figure I'O'is a vertical; transverse; sectional view taken having new andiimproved mechanism for'c larn'pinglthe individual'springs in positionwhile' adjacent rows. thereof are being secured together by helical tie wires.

Another object of my inventionis to'provide a machine wherein all of the wire used in making the helical tie wires: forms an essential part of the'finished assembly with resulting elimination of the scrap ends of'the helical tiewires which heretofore constituted a useless waste and a-danger to employees and others in the plant;

Another object ofmy invention is to providea machine having newand improved mechanism for forming the :11: wire and also showinga crimped end offjsuch wire;

helical tie wires as part of the assembly. operation, and

'for cutting off andclinching the wire so. formed.

Another object of my invention is to provide, a machine havi'ng'new and improved controls whereby the. machine, when once startedby'manualm'anipulation, automatically completes an entire cycle of operations withoutfurther attention on the part'ot the operator. a

Another object of'my invention is. to provide amachine I having 'new and-improved emergency controls which are efiective only'where there is some interference. with the normal operation of themachine and which serve to protect the machine and advise the operator of' such interference.

Anotherobject of'my invention is. to providea machine having novel mechanism for determining the lengthof the helical tie wires;

Otherobjects and advantages will become apparent as the description proceeds. v

Iuuhe drawings:

Figure 131i is a; front elevational view,. with parts cut away; showing the right. hand end of I the machinewith the helicalwire forming mechanism in tilted and stopped position;

Figure ll'a: is" an lever;

Figure 12 is a. View of part of a springassembly produced bythe-machinegi v P Figure 1'3"i's a face view of an end die block showing springsassemhledthereon and" the crimping mechanism for one end ofahelical tie wire; p

Figure 14 is a si'mii'r view of a: die block atthe other end' of the machine showing the means for cutting on exploded view of a, clutch operating Figure 15 is a horizontal section taken. on theline 15- 15 'of Figure*14; Figure-161's a view'showi'ng the manner in' which coils of adjacent springsare secured together by a helicaLtie Figure 1'6ais: a vertica1; transverse, sectional view en on the line I6iz'-j-1'6z 1jof Figure 121; Figure 17 isfan'elevationai view,'partly'cut airway, showing the cutting and crimping. mechanism; Figure lflis a top-planviewofi themecha'nism shown in-Fignre-I-T; Q f

Figure lfia' is an elevational view ofian alternative form of rack-bar; Figure19 is-a top planviewofa wiremeasuring mecha nism'; w Figure 20 is aside elevational view of the-rnechanism of Figurea1'9; ,1 1 r Figurell is; aivertiaksectional view taken on the line 21--2Lo.1?igure20.;; v

lii ure;22I is; a partial; .vertioah sectional view. showing the Pointer fort dit a flgz h z numben of: rows: ofi-springs assembled. and part. oh theldriyingi mechanism for indexe ingthedie blocksp I I V v Figure; 2 3 is.asectipnsirnilarto Figure 2-2: and taken on; the same plane:,butfshOyvinghtherparts of thepointen driving mechanism die block indexing mechanism;

Figure 24 is a sectional view taken generally in the plane of lines 2424 of Figure 23;

Figure 25 is a detail view, partly broken away, to show the ball clutch for thedrive of the die block indexing mechanism;

Figure 26 is a diagrammatic view of the operating mechanism and controls therefor;

' Figure 27 is a vertical, transverse, sectional view similar-to Figure 4, but showing a modified form of my invention, and

Figure 28 is a fragmentary elevational view similar to that of Figure 1 showing a modification in the means for displacing the tie wire forming mechanism into and out of position of use.

In Figure 12 of the drawings, I have shown one phase of aspring assembly of the, type produced by my novel spring assembly machine. In this assembly the individual springs 40 are arranged in parallel rows indicated by the letters A, B, C, D, E and F, and the top coils of each row are securedto the top coils'of an adjacent row by a helical tie wire 42. It will be understood that the bottom coils of the individual springs 40 of each row are similarly connected to the bottom coils of the springs of an adjacent row by a tie wire 42. The spring assembly may have any desired number of horizontal and vertical rows of springs although the particular machine shown herein is limited to spring assemblies having a maximum of ten vertical rows. This machine may be readily adapt- I ed to make spring assemblies having less than ten vertical rows and my invention is equally capable of being embodied in machines for making spring assemblies having more than ten vertical rowsof springs.

My novel machine comprises, ingeneral, a frame having. legs 44 supporting a pair 'of'channel irons 46 (Figures 1 and 4). These channel irons and legs maybe provided with braces as indicated by reference character 45. Vertically disposed transverse plates 48 and 50 are connumber of individual springs required to provide a spring assembly of the desired width.

The die blocks 82 have hardened faces 84, best shown in Figures 4 and 13. Each of these faces has a pair of horizontal channels 86 and 88 adapted to receive the ribs of a clamping bar, and an intermediate horizontal channel 90 for receiving one of the tie wires 42. Each die face also includes an arcuate groove 92 for receiving a portion of an end coil of an upper row of springs 40, and a second arcuate groove 94 for receiving a portion of the end coil of a spring 40 in a lower and immediately adjacent row. It will be noted from Figure 13 that the end coils ofthe springs overlap in the horizontalgroove 90 into which the helical tie wire 42 is fed. An upper set of pins 96 is provided to facilitate the insertion of the spring coil into the arcuate groove 92, and a lower set of pins 98 is provided to assist in locating the end coil of the lower spring into the arcuate groove 94. The pins 98 also guide the clamping mechanism to be hereinafter described.

The die blocks also are provided with vertical channels 100 adapted to cooperate with stripping mechanism which serves to removethe coiled springs from the die blocks as the assembly progresses. The particular die block shown in Figure 13 is one of the die blocks located immediately adjacent the plate 48 and is provided with certain crimping mechanism to be hereinafter described.

Referring to Figure 4, it will be seen that the springs are inserted individually between opposed pairs of spring guides 102, a pair of which is provided for each vertical series of die blocks. In inserting the springs the end coils engage the guides 102 which lead these end coils into engagement with the arcuate grooves 92 in opposing nected to the channel irons 46 by brackets 52. The upper corners of the plates 48 and 50 are connected by angle irons 54, and the intermediate portions of these plates are connected by spaced supporting members 56 (Figure 4).

Referring to Figures 1a and 10, it will be seen that a pair of angle irons 58 have their right hand ends attached to the plate 48 and are supported by braces 60 attached to the left hand legs 44. These angle irons 58, as best shown in Figure 10, support rollers 62 and guide plates 64 which together constitute supporting and guiding means for clamping mechanism which I shall hereinafter describe. 7 g

A tilting head of platform 66 (Figures 1. and 11) is pivotally attached at 68 to the channels and supports the mechanism for feeding and forming the helical tie wires. This head is moved between the horizontal position shown in Figure 1 and the tilted position shown in Figure l1 by an 'air cylinder 69 mounted in a sub-frame 70 attached to the right hand pair of legs 44;

Referring to Figure 4, it will be seen that my machine has two pairs of longitudinally extending shafts '72 and 74, the ends of the shafts being journaled in suitable bearings attached to the plates 48 and 50. Sprockets 76 are carried by the shafts 72 and 74, and these sprockets in turn carryendless chains 78. Two or more chains 78 are provided for each set of shafts 72, 74, and these chains carry bars or rails 80 on which die blocks 82 are mounted at spaced intervals longitudinally of the machine, as best shown in Figure 1'. In the form of my invention illustrated in Figures 1 to 26 inclusive, each pair of shafts 72 and 74 has four bars associated therewith, and each of these bars is illustrated as having ten die blocks 82 spaced lengthwise thereof. It will be un: derstood, however, that the machine can 'be designed so that each die bar carries any desired number of die blocks, the number of die blocks used being determined by the die blocks. The pins 96 prevent the end coils of the springs from being pushed downwardly beyond these arcuate grooves and facilitate the introduction of the end coils into such grooves. In starting a spring assembly a complete row of springs is inserted into the top row of opposing die blocks, as indicated in Figure 4, and then the machine is indexed to rotate the shaft 72 and 74 to move the die blocks downwardly between the sets of shafts from the upper position shown in this figure to the lower position shown in this figure. In so doing, a new set of die blocks is brought into spring receiving position.

As the new set of die blocks moves into spring receiving position, the die blocks engage the upper portions of the coils of the row of springs previously inserted and pins'98 guide the end coils of such previously inserted springs into the arcuate grooves 94. The operator then inserts a new row of springs and the end coils of the previously inserted row of springs are held in overlapping relation by the die blocks, as shown in Figure 13. The operator then closes the switch which initiates the cycle of operations which is automatically carried out by the machine and requires no further attention by the operator. This cycle of operations connects, by helical tie wires, the end coils of the two rows of springs which have been inserted, and indexes the die blocks to receive a new set of springs.

The first step in the cycle of operations is the introduction of clamping means for holding the overlapped end coils of the springs firmly in the die blocks as a prerequisite to securing these coils together by means of helical tie wires. This clamping means is best shown in Figures 4, 5, 6, 7 and 8, and comprises a pair of clamping bars 104 and an actuator bar 106. The actuator rod 106 has plates 108 attached thereto at spaced intervals throughout its length, and each of these plates has a pair of inclined slots 110 in which are located the pins 112 of clamping bars 104. When the clamping bars 104 and actuator bar 106 are not in use they are supported on the rollers 62 carried by the angle irons 58 forming the left hand end of the machine and are located between the guide bars 64 attached to such angle irons (as shown in Figure 10).

The clamping bars 104 and actuator bar 106 are moved to operative or clampingposition by the'piston and piston rod 114 of a pneumatic cylinder 116; ,The piston rod 114 is attachedto the right hand endofathe' actuator bar 106asindicated at 118 (Figure 5). Whenthecylinder 116 is supplied withfiuid-under pressure, theactuator bar 106 is moved to the right and-carries with. it" theclamping bars104; These clamping, bars are in the collapsed'position, that is, with-their pins 112 in the lower ends ofthe slots 110, as viewed in Figure'B. Asshown inFigure 10, guide plates 64 prevent spreading of the clamping bars 104during theirinitial movement, after which-there isno appreciable tendency for these bars 'to spread until their forward movement is retarded in the manner hereinafter described.

As the clampingbarsmoveto-the right between the upper set'of die blockslioldingt the newly introducedrow of springs with their end-coils-in overlapped relation. to theend coils ofa previously; introduced row of springs, the'clamping-bars ride on and are guided by; the pins-9e ofsuch die blocks. Just before th eforward movement of the'clamping bars 104'is completed, the tapered for- Ward ends of these bars come in juxtaposition to atapered shelf 120 of an abutment member 122 (Figures 6 and 6a),.which cams or lifts the clamping bars intoexact alignment with the die'blocks if the pins.98have become bent or for any other reason have failed to maintain these clamping bars in =such alignment. Engagement of the forward endsof the: clamp bars-with abutmentmemher 122- stops the forward movement ofthese: bars, and thereafter continuing movement of actuator bar 106 spreadsthe clamping-barsinto firm engagement with the die block-s and-springcoils located therein;

The clamping bars include hardened plates providing spaced'ribs- 124 and-126 which engage in horizontal channels 86 and 88, respectively, of: the die blocks; Between the ribs 124 and 126-each clampingbar is provided with a face cooperating with the-recesses 90 0f. thedie blocks to formclosed. channels for the helical. tie wires- 42. Spreading-of the clamping mechanism into final position closes a switch associated with 'thebars to initiate the next step in the cycle, which is: the forming of thehelical tie wires and the spinning of these wires about the overlapped endcoils of the springs; The thrust exerted by theclamping-bars 104 against the dieblocksis resistedby engagement of the die blocks-with the inwardly directed faces of guide plates 128 These guide plates are attached. to, and spaced longitudinally of, support' members- 56.

A feature of my inventionlies in the fact that it is only necessary to supply my new and improved. machine withstraight wire in the coiled form in. which such wire comes from the manufacturer, and my machine simultaneously forms this wire into'helic-al form and spins it about the overlapping end coils clamped between the clamping bars and.- die blocks. The wire-is measured as it is formed-into helicalsandvfedinto the machine so that there is-no wastage of wire, and;there are no cut-ofl. sections of helicals tofall on the floor and provide insecure footing for the operator and others-workin'g-near or passing by the machine. Thisfeature of my invention contributes materially to the efliciency and cleanliness of the assembly operation and eliminates the separate forming and intermediate handling of the helical tie Wires. necessitated by prior assembly machines.

Two coils of wire of a sizesuitable for forming the helicaltie wires may be supported-on any suitable means (not shown) adjacent the right-hand eud of the machine, and the wire 130 from each coil isfed'into the machine by. a pair of feed rollers'132 and 134' (Figure 11). The two-pairsof feed rollers are best showniin. Figure'9, each feed roller 132 being mounted on a shaft 136, and each fe'edroller 134 being mounted on-a' shaft 138: The shafts l 36 are mounted in roller bearings carriedv by blocks 140 located in the upper extremity ofa vertical slot 142: provided by a housing 1-44mounted on theplatform-or head 66. Shafts 138* are mounted in similar bearingsxin the blocks. 146 slidable in the slot 142 and. urged -.upwardly byserews148-which force the feed-rollers 1314- toward theifeed rollers 132: The feed-rollers are preferably provided" with grooves: 150 somewhat. shallower. than half the diameter of the wire tobe fed so tha-t-by adjusting the screws 148 any desired frictional engagement; can be secured betweenthe feed rollers andtthe wire. fed thereby. Springs 152 are preferablyyinterposedtbetween the blocks and-the blocks 146;

Each set of feed rollers is. drivenby a'chain-154 (Fig: ures 2 and 9) which passes over 'asprocket 156*on shaft 138, a sprocket-.158 on shaft136,.anrid1er sprocket160, and a driving sprocket lollona jack shaftllfik The jack shafts 164 are mounted in bearings carried in. them;- wardly; extending sides 166 of the housing, 144. andh'ave splined innerends 168 on. which clutchfmembers17 0 *are mounted for longitudinal movement.

InFigure- 9 the clutch members1-70 are shown .iBr-dlS: engaged position but. are adapted. to be independently moved. by clutch levers. 172 into engagementzwith. an:in-. termediate clutch member 174. journaled. on. bearings carriedby the inner: ends of shafts 164 and. heldagainst longitudinal movement by such. bearings. The: clutch member 174 has gear teeth 176 whichmesh'with andsare driven by a'pinion178 mountedon a mainshaft ISO-journaledin bearings in the upper. end. ofthehousing sides 166 and held againstlongitudinal. movement by snap rings 182. Shaft 180 has-a pulley, 184 at one end=there of, and a belt 186 connects the pulley 184-with.-a sm aller pulley 188 driven by a mot0r'190,

The'clutch levers. 172 are. each positively operated in bothdirections by a-solenoid 192: (Figure. 11.), One-.of these clutch I operating levers is shown: in .detail in Figure Ila-and comprises a'pivot pin 194 mounted in blocks-196 attached to thehousing 144-. This lever-has-pins 198 engaging an. annular groove in a clutch member and an actuated end having a central opening. in which there is located the actuating pin 1990f a solenoidl92: 'Iihis opening is formed by complementary recesses 200r and 202, the former being formed in an integral part of' the lever 172 and the latter beingformed in a cooperating plate 204 secured to the lever 102 by bolts passing through registering elongated slots-in the lever and plate whereby the elfective length of the opening formed by-the recesses 200- and 202 02111 be varied to give, the desired clutch adjustment.

Each pair of feed rollers132, 134, draws'a wire 130 from the coil in the form. in which the wire is delivered by the manufacturer and the rollers force this wire through. a forming die 206 (Figure 11). This diemay be of any conventional type and causes the wire to assume the helical-form indicatedat208. Fromthe forming die 206 the helical tie wire is fed into the end-of a tube 210 fixed to the frame plate 50 and in alignment with the channel formed by a clamping bar 104 and the longitudis nal series of die blocks with which it is'engageds As'the helical tie wire is fed through the. tube 210 andchannel just described, this wire rotates.- about. its longitudinal axis and is wrapped-or spun-about the overlappingportionsof the end coils ofthe springs. clamped. between the clamping bar and associated die blocks. The manner in which this tie wire is wrapped about the overlapping coils-is clearlyindicated inFigures 13 and 16. Pins 2I2 and 214 are mounted on each die'block int thechannel 90 to guide the forward end of the helical. tie wire and position it for the desired wrapping or spinning action about the overlapping portions of the spring coils.

As each wire 130 is fed into thev machine by its feed rollers 132 and 134, this wire passes through a-measuring means, indicated generally by the referencecharacter 216 (Figures 1 and 11) which is illustrated most fully in Figures 19, 20 and 21. Each measuring means is ats tached to the housing. 144 and has aframe 218 support+ ing a threaded shaft 220'carryingsthe driving roller 222. An idler 224.: is also grarriecl:by the1frame218 and is ad- 7 justably mounted therein as indicated at 226, whereby the idler 224 can be so positioned as to press the wire 130 against the driving roller 222 with sufficient force to eliminate slippage therebetween. The rollers 222 and 224 are preferably provided with shallow grooves 228 and 230 respectively.

As the threaded shaft 220 is driven by roller 222, the shaft moves a carriage 232 which has a half thread 234 engaging the shaft 220. The carriage 232 is slidable on the frame 218 and is held in engagement with the shaft 220 by a spring 236 whose upper end is attached to the carriage 232. The lower end of the spring 236 is attached to a bar 238 mounted on the housing 70 (Figures 1 and 1l).

An adjustable contact 240 is mounted on carriage 232 and engages the contact 242 of a microswitch 244 when the desired amount of wire has been fed to the machine by the associated pair of feed rollers 132, 134; that is, when the wire fed into the machine has been formed into a helical tie wire and this helical tie wire has been wrapped about the overlapping portions of all of the coils clamped between its clamp bar and the die blocks engaged thereby. The microswitch 244 operates one of the solenoids 192 to open the clutch 170, 174, for its associated feed rollers. While both of the feed roller clutches are being opened by the two microswitches 244, the switches also close a circuit controlling the valve which admits air to the cylinder 246 (Figures la and 16a) which operates the cutting and clinching mechanism shown in detail in Figures 17 and 18.

The'piston rod 248 of the cut-and-clinch cylinder 246 actuates one end of a lever 250 to move this end toward the left, as viewed in Figure 1a. This lever is attached to a cross-shaft 252 mounted in brackets 254 attached to angle irons 58. An arm 256 is attached to each end of the shaft 252 and actuates a slide 258. A spring 260 is attached to each slide 258 and these springs normally hold the slides 258 in retracted position with the associated lever mechanism and piston rod in corresponding positions.

Each slide 258 is in alignment with a rack bar 261 (Figures 17 and 18) carried by the die bar or rail 80, whose die blocks are at the moment engaging one of the clamp bars. The rack bar 261, when moved to the right by the slide 258 as viewed in Figures 17 and 18, operates a pin 262 integral with or attached to the clinch member 264 (Figure 13) and moves this member to the left, as viewed in the latter figure. Such movement forces the forward end of the tie wire 42 back toward a stop block 266 and puts a crimp in the end of the tie wire, as indicated at 268 in Figure 16. This crimp and the corresponding crimp formed at the other end in a manner presently described serves to prevent the tie wire from unwinding from about the overlapped portions of the end coils. V The right-hand movement of the rack bar 261, as viewed in Figures 17 and 18, also rotates a pinion 270 mounted on a shaft supported in the die block 82 shown at the left-hand side of these figures. Rotation of this pinion pulls rack 272 toward the left and with it rod 274 and its associated slide 276. This slide carries a plate 278 which engages a pin 280 attached to the cutter 282 (Figures 14 and 15). When this cutter is moved to the left as viewed in these figures, it coacts with a block 284 to cut the adjacent portion of the helical tie wire 42 and then continues toward the left to force the cut end of the tie wire 42 toward the stationary block 286 and thereby crimp the end of the tie Wire.

The cut-and-clinch slide 276 and its associated mechanism is returned to retracted position by the spring 288 having one end attached to a collar 290 affixed to the rod 274 and its other end attached to the die bar or rail 80. An adjustable stop 292 limits the retractile movement of the cut-and-clinch mechanism. It will be understood that each die-bar 80 and its associated die blocks have attached thereto cut-and-clinch mechanism of the kind illustrated in Figures 17 and 18, but only the cut-and-clinch mechanisms associated with the die blocks currently engaged by the clamping bars are in alignment with the slides 258 for actuation thereby. Only the end die blocks adjacent the vertical frame plate 48 are pro vided with the clinching means 264, 266 of Figure 13, and only the end die blocks adjacent the vertical frame plate 50 are provided With the cutting and clinching means 282, 284, and 286 of Figures 14 and 15.

In order to make the machine adaptable to manufacture spring assemblies of less width, e.g. having less than ten springs in each horizontal row, rack bars 261a (Figure 18a) may be substituted for the rack bars261. Each bar 261a has a plurality of openings 289 adapted to engage a pin 262 of a clinch member 264 associated with a die block. By shifting the pins 262 and clinch members 264 to any one of the three vertical series of die blocks in registry with the openings 289, different widths of assemblies may be produced. The contacts 240 of the tie wire measuring switches will have to be correspondingly adjusted.

As the lever 250 of the cut-and-clinch mechanism completes its operative stroke, it contacts and closes a microswitch 290 (Figure la). This switch operates the valve of clamp bar actuating cylinder 116 to admit air to the right-hand end of the cylinder, as viewed in Figure 5, and return the clamping bars to their original position in contact with the rubber bumper 292. The return movement of the clamping bars permits the switches associated therewith to open and break the motor circuit. The initial movement of the piston rod 114 retracts the actuating bar 106 while the inertia of the clamping bars 104 and the frictional engagement of these bars with the die blocks hold them against return movement. The relative movement between the clamping bars 104 and the actuating bar 106 causes pins 112 to slide in inclined slots 110 so that the clamping bars are drawn inwardly and away from engagement with the die blocks. Continued backward movement of the actuating bar 106 carries the clamping bars with it. As these bars move backwardly they successively engage the switches 294 and 296 (Figure la), each of which has an upstanding arm with a roller positioned at the upper end thereof for engagement by the cam block 298 attached to the clamping bars. In Figure 10, I have illustrated the arm 300 and roller 302 which is engaged by the cam block 298 and serves to actuate the switch 296.

The switch 294 releases the pressure in the cut-and clinch cylinder 246 and permits the springs 260 and 288 to return their respective assemblies to idle positions. This switch 294 also operates a circuit to release pressure from the cylinder 69 beneath the table or head 66, thereby permitting this head and the wire feeding and measuring mechanism carried thereon to drop from the position shown in Figure 1 to the position shown in Figure 11. Downward movement of the head 66 is limited by an adjustable stop 304. A similar adjustable stop 306 determines the upper position of this head. As the head 66 drops, tension on spring 236 is released, and the portion of helical tie wire between the forming die 206 and the cutter associated with the adjacent die block is drawn backwardly an amount sufhcient to compensate for any overrunning of the feed rolls subsequent to the cutting operation. This backward movement also 'Withdraws this portion of the helical tie wire away from the adjacent die block so that there is no interference with the indexing of the die blocks which brings another die bar and its associated die blocks into alignment with the tube 210.

Instead of rocking the head 66 about its pivot 68, the desired displacement of the head 66 between normal position with the helical tie wire aligned with the tie wire channel between the die blocks and retracted position, wherein the helical tie wire between the forming QLBBQL dieltltiv and: the. cutter associated with. the;- adjacent; die block is drawn backwardly. by. an. amount. to compensate for. the, Qverrunning of the feed rolls and, wherein the helical tiewire is withdrawn from between. the adjacent die, blocks. toavoid interference with. the indexing; of thediebloeks, may be achieved, by linean displacem n of. the .head, as illustrated in. the modification-shown. in Figure. 28... i

In. thismodification, the. table; or head .66 1i s.sl PPOI1e1 for linear displacement longitudinally in the direction toward. and. away from the die blocks on. horizontally disposedmays 4.00, rigid with the frame or channelmems, hers; 4.6. and supported at its. forward; end. on.,1egs...40-1-, The piston arm 402 of the air cylinder. 69.! fixed within a. housing. 403.. on the. table .404. is. pivotally engaged; at its. end onto a bracket 405 fixed to. the head. 66. for dis,- placement thereof; between normal or. operative position, indicated by the solid lines, and-retractedposition shown bythe roker lines. in igure 28,- hen=. l sp,1a e.d o retractedposition responsive to=operation ofswitch 224 to ,releasepressurefromv cylinder 69. the-helicaltie Wires a e withdraw r s es ri omt e hedie 1. Upon return of the head to normal or operated pos on correspon in to h a sed posi ion; n hemodifi tion previously described; the helical tie; wires; are returned to between the adjacent die bloc in alig ntgwith the han els. hr u h hi e i wires are: ad anc d; tor. joinin a: et. p i oils.

Qontr s: o h op ra n. o he. cy nde 'fifl fo i pla ment: of h head. 6. betw en nor al 31 e racted po i ion orr pondr y h contr s. for oper tion 0. he y in er! 6.9 hutdns ea of o king; he-head; a a .ts pivot; 68tbetwee inormal; and; r tract dor tilt d-puson, the; head. is: displaced, linearly. between. normal and; no: tracted'position.

Thezrelease of tensionon. springZ-QS permitsrthe mess: uring means to return to initial position and thereby; COD: dltlOIlSi these. means. for. measuring two new. tie: wires when the two pairsofrfeed rollers are again operated. As soon. as the tensionof spring. 236. is. released, springs.-.3.08 raise carriage. 232 so that half thread 234 is out of-engage-- ment with threaded shaft 220; Thereupon, springs 310 return: thecarriage 232 to the startingv position. shown. in Figures: 19 and 20 wherein-.thiscarriage engagescross? member-312 of frame 2 18.

Switch 296, which is closed shortly after the closing: of switch 294, controls the. valve foradmitting the air to the indexingcylinder: 314 (Figure 3). This switch 296 also actuates a solenoid to withdraw latch pin- 316 which normally holds the piston rod 318 oh cylinder- 314 against movement. A rack 320isattachedto piston rod 318; and movement of the piston rod and raclc toward the right in Figure 2; rotates a one-way: clutch 322, shown more fully in Figure 25. This'clutch has balls 324 urged by springs 326 toward the tapered ends of openings 328 formed between the outer clutch member 330 and the inner clutch member 332. When" the clutch member 330 is driven in the direction of the arrows 334; nomotion is transmittedi to the shaft 336 whereas motion-is transmitted to this shaft when the clutch member 33lkisrotated the. opposite direction by rack 32 0.

Shaft336 is connected by sets of beveled gears 3 38 and .0 to h ich d i he h ar ar y n chains 78 in the direction of the arrows 342 and 344 of F u Thus, h right-hand move nt; of, to d 3 and sk .20 as ewedl n F gur 5 indo ss he he bars, o bring new air of. ars n rin r cei n po it o the o e of prin arr cfdie blocks move downwardly. and outwa dly around the' lower sides o ha s r p 46 assis n ra at hs hes he bloclgs from. the springs carried therein. is aecom gl he h u h e nga emen of h nner end oi. the i ip o s h he she l sh: (Figure 1 e he: i b ac s... he. r nger re mante n. raitsr sotally supported inthemachineframe. Springs 350 are attached, byarms 352. to theend pairs of strippers and re located laterally. thereof. to permit, the spring assembly. to bfllwQ lthe springs 350 without interference thereby. These, springs 3,50-a ssi s t in holding the upper ends of the str ppers in. engagement withthe die blocks.

The indexing mechanism also operates an indicating mechani m comprising a movable pointer 354 and a statio ydial; (F gu s 1 and. The p er is d riyenbya;shaft358-havinga toothed wheel 360 (Figure 24) attached to-one end thereof, This toothed wheelie driven y a ear 3 .2 moun ed on shaft 33 and; avinaa ingle: ooth 36 wh ch engage he. o h Wheel 36.0. The construction; of the par is. such h e haf 336. rotates hrough. ne. compl e revo u ion f r h in ex: ing rnoyementand drivesthetoothed wheel 360 one notch. wheel 3.6.0 is engaged by a fing r-v 366. yieldablv urged into; engagement; with the; notches in thewheel 360, bye spring; 36,8, the:p urpose,.of this. mechanism being topre; vent overrunning of the wheel 360 and; to hold the. pointer againstaccidental displacement. A cam 370. is adjustably mounted onthepointer shaft 358 and engages the contact pointof a switch 3'72 which operates light 373 (Figure .1), to indicate to. the operator that a spring. assembly has been completed.

As the piston of the cylinder 314. (Figure 2) completes its. indexing stroke, a. finger 374 engages a microswitch 376 whichadmitsair to the right-hand end of the cylinder 314 and-returns. the indexing mechanism to the position shown in this figure. During such return movement the two parts of-'-the clutch 322 slip with respect to each other and transmit no motion to the shaft 336. The switch 376 also admits air to the cylinder 68 and causes this cylinder to return the: head 66 and its associated mechanism to the upper position shown in Figure 1.

From the time the operator actuated the starting button until the-indexing mechanism and-head 66 had been re-- turnedto normal position, all of the operations were automatically performed in a predetermined sequence and required no attention on the part of the operator. The machinehasnow completed its cycle of operation and is'ready for the insertion of a new row of springs. As soon as such springs have been inserted and the starting button again pressed the cycle of operations is repeated. This procedure is continued until the pointer- 354 and signalflight- 273- advise the operator that the spring asseinbly has been completed. The operator then presses the indexing-switch. Following a single indexing movement of the die bars the machine is ready for the insertion of" the first row of springs of the next spring assembly.

The operator then inserts the first row of springs for the next assembly and immediately presses the indexing button. This releases the last row of springs of the completed assembly from the die blocks and permits this assembly to. be withdrawn from beneath the machine. The operator next inserts a second row of springs and presses the starting button to initiate the normal cycle of operations, and these alternating steps of inserting a row of springs and pressing the starting button are repeated until the new spring assembly is completed.

The air cylinders are provided with conventional air valves which are unbiased and shifted in both directions by electrical coils. These cylinders are supplied with compressed air or any other gas under pressure from any suitable source. As shown in Figure 1a, a filter 378 and a lubricator 380 may be interposed between the air supply line-3 82 and the line 384 leading to the several air cylinders on the machine.

In addition to the controls for carrying out the cycle as heretofore described, I also provide certain emergency controls which become operative only if something interferes with the normal cycle of operations. Referring o F g re 41.; t l e. een hat I have. p e a m cr switch 38. ssociated. with ach, tube 210. If the forward 

